The authors proposed a novel on-machine measurement method for evaluating three-dimensional profiles of machined flat surface: square layout four point (SLFP) method with angle compensation. The SLFP method enables to connect the results of straightness measurements of each scanning line by using additional two sensors and an angle sensor. Numerical simulation showed that the accumulation of zero adjustment error of displacement sensors makes unignorable distortion on the measurement results. Hence, a new calibration method for zero adjustment error was proposed and the validity of the method was confirmed by an experiment.

In this paper, the failure mechanism of a multilayered CVD-diamond coated tool in sintered WC-Co cutting is discussed. In most cases, thick diamond coating is suddenly peeled off only at the rake face in early stage of cutting. This sudden peel-off creates a sharp edge and then excellent cutting ability is given to the cutting tool. Therefore, failure behavior after this peel-off is actually worthy to investigate. Simple model for coating failure progression, which is based on interlaminar fracture, is proposed. From cutting experiments for different types of sintered WC-Co, the model can approximately represent failure behavior of the multilayered CVD diamond coating after large peel-off at the rake face.

We would introduce current status of developments of a reflector facet transmission (RFT) grating for the WFOS (Wide-Field Optical Spectrograph) of the TMT (Thirty Meter Telescope), hybrid grism (direct vision grating) for the MOIRCS (Multi-Objects Infrared Camera and Spectrograph) of the 8.2m Subaru Telescope, and volume binary (VB) grating for an echelle grism of the MOIRCS. We also introduce test fabrications of a birefringence VPH grating with liquid crystals of an UV curable and normal liquid crystal or a resin of visible light curable, and test fabrications of a quasi-Bragg (QB) immersion grating which is combined a QB grating with tilted mirror array, Littrow prism and surface mirror.

This study presents the development of an in-situ hybrid micro-manufacturing process for making a novel micro-tool for the fabrication of a high-precision micro-hole of 200-μm in diameter in difficult-to-machine material. The hybrid techniques approach consists of rotary micro-EDM, micro-EDM peck-drilling, codeposition, reverse micro-w-EDM, and micro-honing, which can all be conducted on a single machining center allowing for in-situ micro-manufacturing. A novel micro grinding-tool which has an invert-tapered forked microstructure with central-symmetry and radial-elasticity is designed and fabricated using the hybrid processes. By applying the principle of cantilever beam support, the micro grinding-tool is employed for honing a micro-hole on SKD11 cold-working steel, achieving micro-scale material removal. All working coordinates are recorded during the process, the micro-tool and -workpiece do not need to be unloaded and repositioned until all planned tasks are completed. Experimental results demonstrate that flatness of the hole-wall, circularity, cylindricity and surface roughness of the honed micro-hole are 1μm, 0.5μm, 1μm and Ra0.032μm, respectively. It is expected that the approach will significantly contribute to the high-precision industry and to future micro fabrication techniques.

Most of the existing studies about production scheduling aim to find an optimum production schedule before starting production activities. However, unpredictable disruptions may occur in the actual manufacturing environment. Therefore, the disturbed production schedule needs to be modified for the unpredictable disruptions. In our previous studies, a reactive scheduling method has been proposed by using a genetic algorithm in order to modify the disturbed production schedule without stopping production activities. However, the proposed scheduling method significantly changes the initial production schedule in the modification process of the production schedule in order to optimize the production schedule. The significant changes of production schedules may confuse the actual manufacturing environment. In this research, we propose a partial modification approach by extending the reactive scheduling method. A hybrid genetic algorithm is developed to improve the disturbed production schedule without greatly changing the initial production schedule. Computational experiments demonstrate that the new method is superior to the previous method.

Vegetable oils are highly biodegradable and non-toxic, pose good lubricating properties and do not require high production costs. In this study, a chemically modified palm olein oil (MRPO) containing additives has been evaluated as a bio-based metalworking fluid (MWF) for machining application. Two types of additives; hexagonal boron nitride nanoparticles and an oil-miscible phosphonium-based ionic liquid (PIL) were added into the MRPO to enhance its machining performance. Orthogonal cutting experiment was conducted with the use of the lubricant samples as the MWFs. A minute quantity of PIL (1 wt. %) is found to increase the machining performance of the MRPO, as well as when compared to the conventional MWF, synthetic ester. MRPO+PIL1% presented good improvements in terms of its physical properties, cutting force and cutting temperature. In conclusion, it was found to be the best mixture formulated as an advanced renewable bio-based lubricant for sustainable machining operations.

The application of laser assisted milling on machining of difficult-to-cut material is proven effective. The workpiece surface is soften by the laser irradiation, thus reduces the cutting force, effectively prolongs the tool life and improves the surface roughness. However, this technique tends to be complicated and unpredictable when dealing with the micro size of the cutting tool. The influence of the cutting tool size, plastic behavior of the workpiece material and thermal variation at the cutting area on the chip formation behavior and machining performance become more pronounce. There are many volatile factors contributed to the fluctuation of cutting force values in machining process, thus impaired the surface roughness. The purpose of this study is to evaluate the efficiency of laser pre-heating process for laser assisted micro ball milling process of Ti6Al4V. In addition, a machining simulation is also applied to characterize the formation of chip and to predict the value of cutting force. The pattern of chips by the simulation is almost comparable with the chip produced by the actual machining. However, the formation of continuous chips and conical chips were unable to be simulated due to some restriction in model construction. The result of cutting force was unable to predict precisely by the simulation. It is suggested that the distinction aroused was due to the assumption input parameters in the simulation, which neglecting the effect of adhesions and tool wear propagation.

Cryogenic machining process is using cryogenic coolant as a cutting fluid in machining process. This technique has proven that can presenting a better performance in heat removal process and can perform well as a corrosion resistance. The cryogenic carbon dioxide (CO₂) liquid is almost exclusively being used. This paper introduces an innovative technique and economical dispensing method that directs CO₂ through micro supercritical carbon dioxide mist spray to the cutting zone. It was focused on the effect of the mixing ratio between CO₂ gas and lubricant for the orthogonal cutting process in terms of spray characteristic, cutting temperature and cutting. The performance of metering valve opening for cryogenic CO₂ is comparable with the fully open metering valve with only approximately 7% decrement in cutting force and temperature values.

Mixed colloidal silica particles as abrasive in slurries have been proposed to improve and realize a high removal rate and smooth surface without subsurface damage, on sapphire chemical mechanical polishing (CMP). Mixed silica particles were fabricated by different sizes of nano-silica particle with the range of pH 7-13. The characteristics of the mixed large and small silica particles has been observed. Dynamic light scattering (DLS) spectra results revealed that the structure of the mixed particle, the small particle at the size of 4 nm are adsorbed on the large silica particles and increase in the size of the abrasive particles. Furthermore, we found that pH value affected to abrasive particle size. In these cases, our polishing tests results show that material removal rate (MRR) of the sapphire CMP totally increase. This confirmed that mixed particles could produce a higher MRR than single colloidal silica slurry. Finally, the mechanism of sapphire removal was discussed.